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Research Summary Report A03
Extrusion of Near-Nozzle Mixed Concrete –Individually Graded in Density and in Rate of 3D Fibre Reinforcement [26.08.2022] Hechtl, Christian Maximilian, TP editor, m.hechtl@tum.de, TUM, Chair of Materials Science and Testing (cbm) Dr.-Ing. Matthäus, Carla, TP editor, c.matthaeus@tum.de, TUM, cbm Dr.-Ing. Kränkel, Thomas, PL, thomas.kraenkel@tum.de, TUM, cbm Prof. Dr.-Ing. Gehlen, Christoph, PL, gehlen@tum.de, TUM, cbm The goal of A03 is to establish a concrete extrusion process using a near nozzle mixing approach to enable the change of material properties while printing (gradation). With this approach multifunctional components can be realized. For example, a component can simultaneously fulfill load-bearing and thermal insulation functions by locally changing the material properties. Current state of research The second iteration of the Gradation-ready Extrusion System …
Girlspower at the AMC Lab in Achering
#Girlspower at the AMC Lab -german version below- #Girlspower at the AMC Lab in Achering, TU München. Schoolgirls recently conducted research as part of the program “TUM Entdeckerinnen: MINT experience at university” themselves on 3D printing in construction. Next to several other helpers our colleague Maximilian Dahlenburg supervised the girls due to his sub-project “Extrusion of jet-mixed concrete – individually graded in bulk density and 3D fiber reinforcement” as part of the collaborative research project AMC – TRR 277 “Additive manufacturing in construction”. The girls learned about the process of basic research and were allowed to print an electronic random cube themselves. Munich, August 2022 About the AMC: The Collaborative Research Center Transregio TRR 277 Additive Manufacturing in Construction (AMC) …
Research Summary Report B04
Process Control and Adaptive Path Planning for Additive Manufacturing Processes Based on Industrial Robots with an Extended Degree of Freedom [19.08.2022] Lachmayer, Lukas; Doctoral researcher, lachmayer@match.uni-hannover.de Leibniz Universität Hannover, Institute of Assembly Technology (match) Function integration, topology optimization and automation increase productivity through the reduced workload, sustainability by less applied material and safety by decreasing manual labour. These benefits are condensed in most additive manufacturing processes, and thus, these are of significant interest to the construction industry. However, the time- and environment-dependent material properties of fresh concrete reduce the predictability of the material and thus often lead to component collapses during the manufacturing process. This project aims to achieve repeatability within concrete-based robot-guided additive manufacturing processes. Summary As expected and …
Research Summary Report C01
Bridging Scales – From Geometric Part Details to Construction Elements [16.08.2022] Kollmannsberger, Stefan; PL, stefan.kollmannsberger@tum.de, TUM, CMS Rank, Ernst; PL, ernst.rank@tum.de, TUM, Institute for Advanced Study Oztoprak, Oguz; WiMi, oguz.oztoprak@tum.de, TUM, CMS Digital models for Additive Manufacturing (AM) must consider many different geometric scales. The scales range from micrometers up to tens of meters for metal- or concrete-based processes. The TP C01 aims to develop consistent geometric and computational descriptions for the relevant AM products on all of these scales. Based on the multiscale geometric models developed in earlier phases of this research project, we are now focusing on efficient simulation methods for AM products in construction with special emphasis on validation of the developed techniques. Summary The advances …
Additive Fertigung im Bauwesen verankert sich in der Lehre
Additive Fertigung im Bauwesen verankert sich in der Lehre – praktische Anwendungsfälle im Masterkurs Studierende des Bauingenieurwesens an der TUM hatten im Sommersemester 2022 die Gelegenheit, sich mit der additiven Fertigung im Bauwesen zu beschäftigen. Unter der Leitung von Klaudius Henke, Bettina Saile, Daniel Talke und Birger Buschmann, vom Lehrstuhl für Holzbau und Baukonstruktion an der TUM ging es im Master-Kurs „Einführung in die additive Fertigung im Bauwesen“ zentral um das Thema „Additiv gefertigte Brücken“. Nachdem sich die Studierenden mit Referaten über bereits gebaute Beispiele in die Thematik eingearbeitet hatten, vertieften sie den Stoff durch eigene Entwürfe von additiv gefertigten Brücken. Bei diesen Brücken sollte das im Teilprojekt A08 entwickelte Verfahren ‚Individual Layer Fabrication (ILF)‘ zur additiven Fertigung von Holzwerkstoffelementen …
Research Summary Report A02
Particle-Bed 3D Printing by Selective Cement Paste Intrusion (SPI) – Particle Surface Functionalisation, Particle Synthesis and Integration of WAAM Reinforcement [09.08.2022] Straßer, Alexander, TP editor, alexander.strasser@tum.de, TUM, Chair of Materials Science and Testing Matthäus, Carla, TP editor, c.matthaeus.@tum.de, TUM, Chair of Materials Science and Testing Kränkel, Thomas, TP editor, thomas.kraenkel@tum.de, TUM, Chair of Materials Science and Testing Gehlen, Christoph, PL, gehlen@tum.de, TUM, Chair of Materials Science and Testing The goal of A02 is to implement reinforcement by Wire and Arc Additive Manufacturing (WAAM) in concrete elements produced by Selective Paste Intrusion (SPI), see Figure 1. Since the cement paste is applied to the aggregates and must penetrate the cavities between the aggregates by gravity, consistent rheological properties of the cement …
Research Summary Report B03
Modelling and Simulation of Shotcrete 3D Printing (SC3DP) Based on a Massively Parallel Multi-Phase, Multi-Component Coupled LBM-DEM Approach [26.07.2022] Kutscher, Konstantin; Researcher Geier, Martin; Project leader Krafczyk, Manfred; Project leader all: TU Braunschweig, Institut für rechnergestützte Modellierung im Bauingenieurwesen (IRMB) B03 goals The primary aim of the project is to understand and quantify the dynamic distribution of material components (fluid, air and particles) and kinetic energy inside the jet of liquid concrete present in the shotcrete process. The information is required as a basis for future optimization of the process with regards to process and material parameters as well as for the prediction of material inhomogeneities. Summary The application of the conservative phase field method to the modeling of droplets …
Research Summary Report A01
Particle-Bed 3D Printing by Selective Cement Activation (SCA) – Particle Surface Functionalisation, Particle-Bed Compaction and Reinforcement Implementation [15.07.2022] Herding, Friedrich; Researcher, f.herding@ibmb.tu-bs.de Mai, Inka; Leading researcher, i.mai@ibmb.tu-bs.de Lowke, Dirk; Project leader, d.lowke@ibmb.tu bs.de all: TU Braunschweig, Institute of Building Materials, Concrete Construction and Fire Safety (iBMB) The main objective of our research in TP A01 is to understand the material-process-interactions in particle bed 3D printing by Selective Cement Activation (SCA) in order to produce concrete elements with high mechanical strength and geometric precision. Besides, we are also investigating different ways of reinforcement integration, which is crucial for the manufacturing of load-bearing building components. Summary In Particle Bed 3D Printing (PB3DP) by Selective Cement Activation the water to cement ratio (w/c‑ratio) …
Research Summary Report C05
Jointing Principles for Combination of Concrete Elements Produced by Different Additive Manufacturing Processes [12.07.2022] The Technical University of Braunschweig, Institute of Structural Design (ITE) Prof. Dr. Harald Kloft.eng (ITE) Prof. Dr. Martin Empelmann.eng (iBMB) Author: Abtin Baghdadi a.baghdadi@tu-braunschweig.de Researchers: Jan-Paul Lanwer, Hendrik Weigel (iBMB), Abtin Baghdadi (ITE) This project, as close cooperation between ITE and iBMB (Concrete-Construction) by subtractive robotic process, aims to investigate the jointing principle to combine different additively manufactured elements. C05 investigates the execution process and load-bearing capacity of the concrete milled dry joints, considering different concrete printing techniques to be utilized in the construction of prefabricated structures. Accordingly, C05 mainly investigates the application of the post-processing grinding technique (milling and cutting) for developing innovative connections and …
AMC-Scientists awarded with two international prizes for outstanding research
At this year’s Digital Concrete (DC 2022) in Loughborough, the leading international conference for digital fabrication with concrete, scientists from the Collaborative Research Center TRR 277 Additive Manufacturing in Construction (AMC) were honored with two awards. Dr. Inka Mai, M.Sc Friedrich Herding and Prof. Dr.-Ing. Dirk Lowke from the iBMB at TU Braunschweig won the Best Paper Award for their evaluation of the use of methyl cellulose for selective cement activation. Their paper entitled “Evaluating the Effect of Methyl Cellulose on Hardened State Properties in Selective Cement Activation” convinced the jury. Likewise, M.Sc. Yinan Xiao from the ITE of the TU Braunschweig was able to accept the prize for the Best Student Presentation. He presented the paper “Injection 3D Printing …
Research Summary Report C04
Integrating Digital Design and Additive Manufacturing through BIM-Based Decision Support and Digital Twin Methods [05.07.2022] Borrmann, André, Project leader, andre.borrmann@tum.de, Technical University of Munich, Chair of Computational Modeling and Simulation; Slepicka, Martin, Researcher, martin.slepicka@tum.de, Technical University of Munich, Chair of Computational Modeling and Simulation; Computer Aided Manufacturing (CAM) methods, such as Additive Manufacturing (AM), are becoming increasingly popular in the construction industry, since they offer more geometrical freedom than conventional methods. However, more complex data preparation is required for these methods and thus they have been considered separately from digital design so far. To increase the usefulness of AM for the industry, this project aims to integrate AM methods into the digital design methodology BIM. To achieve this, a framework …
Digitaltag 2022
Digitaltag 2022 Der AMC hat beim diesjährigen, bundesweiten Digitaltag teilgenommen. Unter dem Motto „fun with technology -Exkursion zum Beton 3D-Druck“ konnten Schüler:innen Forschung und technologische Weiterentwicklung des 3D-Drucks miterleben. Was ist mit einem 3D-Drucker alles möglich? Was sind die Vorteile? Was sind die Herausforderungen des digitalen Bauens? Und was gibt es für vollkommen neue, digitale Berufsfelder, die durch den 3D-Druck entstehen? Die Schüler:innen erhielten Einblick in die innovativer Forschung, für ein zukunftfähiges Bauwesen. Mehr Informationen zum Digitaltag 2022 finden Sie unter: https://www.braunschweig.de/digitalisierung-online-services/digitaltag-2022.php Braunschweig, Juni 2022 Über den AMC: Der Sonderforschungsbereich Transregio TRR 277 Additive Manufacturing in Construction (AMC) hat zum Ziel, die Additive Fertigung (den 3D-Druck) als neuartige digitale Fertigungstechnologie für das Bauwesen grundlegend zu erforschen. In dem interdisziplinären, …
Ministerbesuch beim Digital Building Fabrication Laboratory
Der niedersächsische Minister für Umwelt, Energie, Bauen und Klimaschutz Olaf Lies und die Braunschweiger Landtagsabgeordnete Anette Schütze informierten sich im Zuge der ersten Sommerreise des Ministers über grundlegende wissenschaftliche Forschungsvorhaben an der TU Braunschweig. Eine Station des Ministers war das Digital Building Fabrication Laboratory (DBFL) des Instituts für Tragwerksentwurf. Dort nutzten Lies und Schütze die Gelegenheit, Einblicke in die Forschung der additiven Fertigung, dem 3D-Druck im Bauwesen zu erhalten und den Sonderforschungsbereich TRR 277 Additive Manufacturing in Construction (AMC) kennenzulernen. Sowohl Lies als auch Schütze betonten die Notwendigkeit, universitäre Forschungsergebnisse besser zu nutzen und stärker in die Gesellschaft hineinzutragen. Für beide Politiker gilt der Grundsatz: exzellente Forschung kann bei gesellschaftlichen Wandlungsprozessen einen großen Beitrag leisten. Konkret wurden dem Minister und …
Prof. Dr.-Ing. Harald Kloft Lecture on the topic: Building the future
The lecture series of the Academy Lectures in the Castle will take a look at the past, present and future of technological developments and their exciting relationship to processes of change in society: Technological Change and Society,” in 2022 will use thematic spotlights to take a look at the past, present and future of technological developments and their exciting relationship to processes of change in society. Prof. Dr.-Ing. Harald Kloft, Institute for Structural Design at the TU Braunschweig, will speak on Wednesday, June 22, 2022 from 18:30 – 19: 30 in the Red Salon in the castle of Braunschweig on the topic of “Building of the future: digitalized, individualized and climate-friendly”. A detailed abstract on the content can be found …
Research Summary Report A02
Particle-Bed 3D Printing by Selective Cement Paste Intrusion (SPI) – Particle Surface Functionalisation, Particle Synthesis and Integration of WAAM Reinforcement [17.06.2022] Hamilton, Leigh Duncan; Researcher; Leigh-Duncan.Hamilton@tu-braunschweig.de Zetzener, Harald; Leading researcher; H.Zetzener@tu-braunschweig.de Kwade, Arno; Project leader; A.Kwade@tu-braunschweig.de TU Braunschweig, Institute for Particle Technology Our research mission for A02 is the implementation of Wire and Arc Additive Manufacturing (WAAM) as a means of simultaneously printing the reinforcement during the particle bed concrete 3D-printing method selective paste intrusion (SPI). The combination of SPI and WAAM is accompanied by obstacles that must be overcome in order to ensure collaborated functionality. One major challenge occurs from the propagated thermal load of WAAM (approx. 1600 °C), which has negative effects on the paste rheology and resulting …
Research Summary Report A05
Integration of Individualized Prefabricated Fibre Reinforcement in Additive Manufacturing with Concrete [10.06.2022] Rothe, Tom; Doctoral researcher, t.rothe@tu-braunschweig.de, TU Braunschweig, Institute for Mechanics and Adaptronics (IMA) Prof. Hühne, Christian; Project Leader, Christian.Huehne@tu-braunschweig.de, TU Braunschweig, Institute for Mechanics and Adaptronics (IMA) The individual integration of fibre reinforcement into large concrete components produced by Additive Manufacturing (AM) allows new design freedoms and reduces concrete consumption due to the lower cover height. The project A05 develops strategies to integrate freely formable reinforcement strands for the different AM processes of the AMC. For doing so, a Dynamic Winding Machine is developed and constantly updated. Thus, fibre strands can be adapted for different purposes and enables more efficient and easier production of highly customised, reinforced concrete …
Research Summary Report A06
Laser Powder-Bed Fusion (LPBF) of Steel Elements for Construction – Basics of Design and Mechanical Resilience [03.06.2022] Wenzler, David; Doctoral researcher; david.wenzler@tum.de Technical University of Munich, Institute for Machine Tools and Industrial Management Diller, Johannes; Doctoral researcher; johannes.diller@tum.de, Siebert, Dorina; Doctoral researcher; dorina.siebert@tum.de Technical University of Munich, Chair of Metal Structures The project A06 aims to explore and evaluate the factors influencing the manufacturing of safe and durable structural steel elements by Powder Bed Fusion of Metals using a Laser Beam (PBF-LB/M). Thereby, the PBF-LB/M process, the post-treatment, and the geometrical aspects in terms of microstructure and mechanical properties will be investigated and correlations will be determined. In the first funding period, the project is focused on analyzing small-scale …
Research Summary Report A04
Integrated Additive Manufacturing Processes for Reinforced Shotcrete 3D Printing (SC3DP) Elements with Precise Surface Quality [25.05.2022] David, Martin; Doctoral Researcher, m.david@tu-braunschweig.de TU Braunschweig, Institute for Machine Tools and Production Technology (IWF) Project A04 aims to investigate cooperative Additive Manufacturing (AM) processes based on Shotcrete 3D Printing (SC3DP) for the production of material-efficient, force-optimized, reinforced, load-bearing concrete components with precise surface quality and geometrical precision. The goal is to produce large-scale concrete elements using significantly lower amounts of reinforcement and concrete as compared to standard concrete construction principles. Hereby, different robot guided end effectors are used for flexible and automated processes. Summary Within SC3DP many process parameters, like volume of sprayed concrete, air volume flow, nozzle to strand distance and …
Research Summary Report A07
Wire and Arc Additive Manufacturing (WAAM) of complex individualized steel components [20.05.2022] Jahns, Hendrik; Doctoral researcher Unglaub, Julian, Senior researcher Institute of Steel Structures, Technische Universität Braunschweig In project A07 the design, manufacturing and mechanical performence of complex individualized WAAM steel nodes for use in construction is investigated. A new method is developed to design force flow optimized steel nodes as connectors between semi-finished parts and anchorage structures considering the manufacturing possibilities of the WAAM-process and the resulting material behaviour. The manufacturing possibilities will be identified by case study demonstrators, which represent occurring features of the designed node. The produced parts are characterized regarding their mechanical properties. For that an advanced material testing method was developed to evaluate the potentially …
Research Summary Report A08
Structural Timber by Individual Layer Fabrication (ILF) [13.05.2022] Asshoff, Carsten; Doctoral researcher;carsten.asshoff@wki.fraunhofer.de Fraunhofer Institute for Wood Research Wilhelm-Klauditz-Institut WKI The main goal of the project ’A08 – Structural Timber by Individual Layer Fabrication (ILF)’ is to develop a process to additively manufacture large-scale, wood composite objects with a maximum content of wood material and strength values suited for applications in construction. In the course of the project multiple process variants and material combinations are explored. For this, the necessary machinery is developed in iterative steps and the mechanical properties of the resulting objects as well as the geometric capacity of the processes are investigated. Finally, multiple demonstrators are fabricated for showcase purposes. Summary Working group Bunzel is researching the process …
